U.S. patent number 8,546,278 [Application Number 11/904,799] was granted by the patent office on 2013-10-01 for composite board containing glass fiber mat.
This patent grant is currently assigned to Johns Manville. The grantee listed for this patent is Duane Paradis, Mandy B. Schweitzer. Invention is credited to Duane Paradis, Mandy B. Schweitzer.
United States Patent |
8,546,278 |
Paradis , et al. |
October 1, 2013 |
Composite board containing glass fiber mat
Abstract
A composite board including: at least one glass fiber mat having
an upper surface and a lower surface; a foam layer attached to the
glass fiber mat; and a first binding composition applied to the
upper surface of the at least one glass fiber mat and a second
binding composition applied to the lower surface of the at least
one glass fiber mat, the first and second binding compositions
being the same or different compositions.
Inventors: |
Paradis; Duane (Highlands
Ranch, CO), Schweitzer; Mandy B. (Westminster, CO) |
Applicant: |
Name |
City |
State |
Country |
Type |
Paradis; Duane
Schweitzer; Mandy B. |
Highlands Ranch
Westminster |
CO
CO |
US
US |
|
|
Assignee: |
Johns Manville (Denver,
CO)
|
Family
ID: |
40583204 |
Appl.
No.: |
11/904,799 |
Filed: |
September 28, 2007 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20090110885 A1 |
Apr 30, 2009 |
|
Current U.S.
Class: |
442/65; 442/68;
442/66; 442/45; 428/160; 442/180; 442/64 |
Current CPC
Class: |
B32B
5/28 (20130101); B32B 5/26 (20130101); B32B
5/18 (20130101); E04B 1/625 (20130101); Y10T
442/2049 (20150401); Y10T 442/176 (20150401); Y10T
442/2074 (20150401); Y10T 428/24504 (20150115); Y10T
442/2041 (20150401); Y10T 442/2066 (20150401); Y10T
442/2992 (20150401); Y10T 156/10 (20150115); Y10T
428/24496 (20150115); Y10T 442/2057 (20150401); Y10T
428/24512 (20150115) |
Current International
Class: |
B32B
17/10 (20060101) |
Field of
Search: |
;428/160
;442/45,64,65,66,68,180 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Choi; Peter Y
Attorney, Agent or Firm: Touslee; Robert D.
Claims
The invention claimed is:
1. A composite board comprising: at least one glass fiber mat
having an upper surface and a lower surface; a foam layer attached
to the glass fiber mat; and a first binding composition applied to
the upper surface of the at least one glass fiber mat which
penetrates into the glass fiber mat beyond the upper surface, and a
second binding composition applied to the lower surface of the at
least one glass fiber mat which penetrates into the glass fiber mat
beyond the lower surface, the first and second binding compositions
being the same or different compositions, and the air permeability
of the at least one glass fiber mat on which the first and second
compositions have been applied is such that it takes at least 300
seconds for 300 cubic centimeters of air to pass through 1 square
inch of the glass fiber mat.
2. The composite board according to claim 1, wherein the at least
one glass fiber mat comprises first and second glass fiber mats,
the foam layer being arranged between the first and second glass
fiber mats and attached to each of the first and second glass fiber
mats.
3. The composite board according to claim 1, wherein the first
and/or second binding compositions penetrates into the glass fiber
mat in an amount of at least 85%, based on the total thickness of
the glass fiber mat.
4. The composite board according to claim 1, wherein the total
penetration of the first and second binding compositions into the
glass fiber mat is at least 85%, based on the total thickness of
the glass fiber mat.
5. The composite board according to claim 1, wherein the glass
fiber mat is substantially completely impregnated with the first
and/or second binding compositions.
6. The composite board according to claim 1, wherein the foam layer
comprises a thermosetting polymer foam.
7. The composite board according to claim 1, wherein the foam layer
comprises polyisocyanurate foam.
8. The composite board according to claim 7, wherein the
polyisocyanurate foam has a density of from about 1.5 pounds per
cubic foot to about 25 pounds per cubic foot.
9. The composite board according to claim 1, wherein the foam layer
has a thickness of from about 0.125 inch to about 6 inches.
10. The composite board according to claim 7, wherein the glass
fiber mat has a thickness of from about 0.015 inch to about 0.05
inch.
11. The composite board according to claim 1, wherein each of the
first and second binding compositions comprises a binder and an
inorganic filler.
12. The composite board according to claim 11, wherein the binder
comprises a latex.
13. The composite board according to claim 12, wherein the binder
comprises a styrene butadiene rubber latex.
14. The composite board according to claim 12, wherein each of the
first and second binding compositions further comprises a secondary
organic binder.
15. The composite board according to claim 12, wherein each of the
first and second binding compositions comprises from about 1% latex
to about 15% latex, based on the respective weight of each binding
composition.
16. The composite board according to claim 15, wherein each of the
first and second binding compositions comprises from about 1% latex
to about 5% latex, based on the respective weight of each binding
composition.
17. The composite board according to claim 11, wherein the
inorganic filler is selected from the group consisting of calcium
carbonate, clay, talc, mica, perlite, hollow ceramic spheres and a
combination thereof.
18. The composite board according to claim 1, wherein the at least
one glass fiber mat has a weight of from about 50 grams per square
meter to about 150 grams per square meter.
19. The composite board according to claim 1, wherein the at least
one glass fiber mat has a coat weight of from about 350 grams per
square meter to about 800 grams per square meter.
20. The composite board of claim 1, wherein the first and second
binding compositions are different.
21. The composite board of claim 20, wherein the different binding
compositions provide different properties to the glass mat.
Description
BACKGROUND
Many types of weather-resistant sheet materials are available for
use in the building construction industry. For example, webbed
sheets including tar paper and spun-bonded polyolefin house wraps
are available for use as an underlayment under shingles or siding
or facers for foamed insulation board laminates. In the past,
webbed sheets have been made with cellulostic felt or Kraft paper
which has been treated with either coal tar pitch, asphalt, or pine
rosin. However, such cellulostic products typically lose their
desired flatness upon contact with water, organic liquid, or other
types of moisture. Similar cellulostic products are flammable and
can therefore constitute fire safety hazards.
Glass fiber mats made of non-woven glass fibers can be used in
place of the cellulose sheets as the facer material in laminates.
In comparison with cellulose products, glass fiber mats can provide
improved resistance to liquid penetration. Glass fiber mats can
also maintain their shape and form upon contact with liquids and
provide improved flame retardant characteristics in comparison with
cellulose products.
A conventional glass fiber mat-containing laminate or composite
board can have an inner layer of material set between two, outer
layers of glass fiber mats. The outer surface of each glass fiber
mat can be coated with a coating material to reduce porosity and
increase resistance to liquid penetration. The inner surface of
each glass fiber mat remains uncoated and is directly attached to
the inner layer material.
Conventional glass fiber mat-containing laminate or composite
boards typically exhibit undesirable characteristics such as, for
example, insufficient mechanical strength, which can cause problems
during the installation, use and/or maintenance of the products.
For example, in roofing underlayment applications, the laminate or
composite board is attached to a roofing membrane. When the roofing
membrane is peeled away from the laminate/composite board, for
example, to conduct maintenance on the roof, portions of the
laminate/composite board can tear away with the roofing membrane
due to the insufficient mechanical strength thereof. Additionally,
conventional laminate/composite boards are typically susceptible to
deterioration when used in high-pH applications, such as tile
backing. A further disadvantage of employing conventional
laminate/composite boards is that when the glass fiber mat is
adhered to an insulating foam during manufacture, the surface
intended to be adhered to the foam typically consumes insulating
foam, thereby increasing manufacturing time and consumption of
materials.
SUMMARY
According to one aspect, a composite board is provided
comprising:
at least one glass fiber mat having an upper surface and a lower
surface;
a foam layer attached to the at least one glass fiber mat; and
a first binding composition applied to the upper surface of the at
least one glass fiber mat and a second binding composition applied
to the lower surface of the at least one glass fiber mat, the first
and second binding compositions being the same or different
compositions.
According to another aspect, a method of making a composite board
is provided comprising:
applying a first binding composition to an upper surface of at
least one glass fiber mat;
applying a second binding composition to a lower surface of the at
least one glass fiber mat, wherein the first and second binding
compositions are the same or different compositions; and
attaching a foam layer to the at least one glass fiber mat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an exemplary composite board,
according to one aspect of the present invention.
FIG. 2 is a schematic view of an exemplary roll coating apparatus
utilized in coating a glass fiber mat, according to one aspect of
the present invention.
FIG. 3 is a schematic view of an exemplary air spraying apparatus
utilized in coating a glass fiber mat, according to one aspect of
the present invention.
FIG. 4 is a cross-sectional view of an exemplary composite board
according to one aspect of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, an exemplary composite board 10 comprises at
least one glass fiber mat 20 and a foam layer 30 attached to the at
least one glass fiber mat. The at least one glass fiber mat has an
upper surface 22 and a lower surface 24. While the foam layer 30 is
shown as being attached to the upper surface 22, it will be
understood that a foam layer 30 can additionally or alternatively
be attached to the lower surface 24.
The glass fiber mat 20 can include glass fibers and a binder which
binds the glass fibers together and maintains the fibers in a mat
form. Any type of glass fiber mat can be used in the composite
board. For example, a non-woven glass fiber mat can be made with
glass fibers and bonded with an aqueous thermosetting resin such
as, for example, urea formaldehyde or phenolic resole resins. The
glass fiber mat can be formed from any suitable process. For
example, these glass fiber mats can be formed from an aqueous
dispersion of glass fibers. In such process, a resin binder can be
applied to a wet non-woven web of fibers and after removing excess
binder and water, the web can be dried and heated to cure the resin
binder to form the non-woven mat product. Non-woven glass fiber
mats can also be made by chopping dry strands of glass fibers bound
together with a binder to form chopped strand, collecting the
chopped strand on a moving conveyor in a random pattern, and
bonding the chopped strand together at their crossings by dusting a
dry, powdered thermoplastic binder like a polyamide, polyester, or
ethylene vinyl acetate on wetted chopped strands followed by drying
and curing the binder.
The dimensional and weight characteristics of the glass fiber mat
20 are not particularly limited, and can depend on the specific
application and desired properties of the composite board. For
example, the basis weight of the glass fiber mat 20 can be from
about 50 grams per square meter to about 150 grams per square
meter. The thickness of the glass fiber mat 20 can be, for example,
from about 0.015 inch to about 0.05 inch. The basis weight and
thickness characteristics can be adjusted depending upon the
desired rigidity, strength and weight of the composite board.
The glass fiber mat is formed from glass fibers. The length and
diameter dimensions of such glass fibers are not particularly
limited and can be selected based on, for example, the intended
application and desired properties of the glass fiber mat. For
example, the flexibility and rigidity of the glass fiber mat can
depend on the selection of the dimensions of the fibers. Greater
fiber diameters and fiber lengths can typically lead to a more
rigid mat, whereas lesser fiber diameters and shorter fiber lengths
can generally lead to a more flexible mat. The type of glass used
to form the glass fibers is not particularly limited, and in an
exemplary embodiment the glass fibers can be formed from E
glass.
The foam layer 30 can be made of any suitable foam such as, for
example, a thermosetting polymer foam. Examples of the
thermosetting polymer foam include expanded polystyrene foam,
polyurethane foam, phenolic foam, polyisocyanurate foam and
combinations thereof. In an exemplary embodiment, the foam layer 30
includes polyisocyanurate foam. The foam layer 30 can also include
at least one filler and/or extender such as a mineral filler. The
characteristics of the foam layer 30 such as the thickness and
density thereof can depend on the particular application and
desired rigidity and strength characteristics of the composite
board. For example, the foam layer can have a density of from about
1.5 pounds per cubic foot to about 25 pounds per cubic foot. The
foam layer can have a thickness of from about 0.125 inch to about 6
inches.
The composite board 10 also includes a binding composition applied
to the upper and lower surfaces of the glass fiber mat 20. For
example, a first binding composition can be applied to the upper
surface 22 of the glass fiber mat 10 and a second binding
composition can be applied to the lower surface 24 of the glass
fiber mat 10. The first and second binding compositions can be the
same as or different from each other, and in an exemplary
embodiment, the first and second binding compositions are the same
compositions.
The foam layer 30 is preferably attached to the at least one glass
fiber mat 20. By being attached to the glass fiber mat 20, the foam
layer 30 can either be in direct contact with the glass fiber mat
20 and/or be adhered to the glass fiber mat 20 via the first and/or
second binding composition applied to the glass fiber mat 20. In an
exemplary embodiment, substantially an entire major surface of the
foam layer 30 is attached to the glass fiber mat 20 via the first
and/or second binding composition.
Referring to FIG. 1, the first and second binding compositions can
form coatings 40 and 42 on the upper and lower surfaces 22 and 24
of the glass fiber mat 10, respectively. In an exemplary
embodiment, one or both of the first and second binding
compositions penetrate into the glass fiber mat 20 beyond the upper
and lower surfaces 22 and 24 thereof, respectively. That is, in
such embodiment, one or both of the first and second binding
compositions do not merely remain at the surfaces of the glass
fiber mat 20. The first and second binding compositions can be of a
material that facilitates the penetration of the compositions into
the glass fiber mat 20. The extent of the penetration of the first
and second compositions can depend on the desired characteristics
of the composite board 10. For example, each of the first and
second binding compositions can penetrate into the glass fiber mat
20 in an amount of at least about 85%, based on the total thickness
of the glass fiber mat 20. In one embodiment, the combined
penetration of the first and second binding compositions can be
from about 85% to 100%, based on the total thickness of the at
least one glass fiber mat 20. For example, in an exemplary
embodiment, the combined penetration of the first and second
binding compositions is to such a degree that the glass fiber mat
20 is substantially completely impregnated with the first and/or
second binding compositions. The extent of penetration of the first
and second compositions can be substantially the same or different.
In an exemplary embodiment, the first and second binding
compositions can penetrate substantially evenly and uniformly into
the at least one glass fiber mat 20.
According to one embodiment, the at least one glass fiber mat can
have a coat weight from about 350 grams per square meter to about
800 grams per square meter. According to another embodiment, the at
least one glass fiber mat has a coat weight greater than 800 grams
per square meter. As used herein, the term "coat weight" means the
weight of the coating per area of the at least one glass fiber
mat.
The penetration of the first and second binding compositions into
the glass fiber mat can, for example, be effective to improve the
mechanical strength of the composite board. While conventional
glass fiber mats have been susceptible to mechanical failure when
used in certain applications, the dual-sided application and
penetration of the binding compositions can be effective to reduce
or eliminate the occurrence of such mechanical failure. For
example, the glass fiber mats can have enhanced tensile strength
and tear strength. The composite board can have improved
characteristics such as increased flexural strength. The binding
composition in contact with the foam layer can increase the
strength of the bond between the foam layer and the at least one
glass fiber mat. That is, in an exemplary embodiment, the foam
layer is attached to the glass fiber mat via the first and/or
second binding composition. Therefore, the glass fiber mat can be
less likely to peel away from the foam layer when a membrane, such
as a single ply roofing membrane or a water proofing membrane, is
adhered to the free surface of at least one glass mat and later
removed. For example, the binding composition in contact with the
foam layer can promote adhesion between the membrane and the glass
fiber mat. The composite board can also have improved flexural
strength. The composite board can have improved pull through
resistance and improved wind uplift performance when installed on
low slope roofs. Additionally, the composite board can have a
larger bending radius.
In addition, the penetration of the first and second binding
compositions into the glass fiber mat can, for example, be
effective to improve the degree of liquid and vapor resistance,
which can in turn improve the weather resistance of the composite
board. The degree of penetration of the compositions and the
permeability of the glass fiber mat can be measured by the air
permeability therethrough, and in an exemplary embodiment the air
permeability of a single coated glass fiber mat used in the
composite board is such that it takes at least 300 seconds for 300
cubic centimeters of air to pass through 1 square inch of the glass
fiber mat. For example, if the composite board has a foam layer
arranged between a first glass fiber mat and a second glass fiber
mat, preferably the air permeability of each of the first and
second coated glass fiber mats is such that it takes at least 300
seconds for 300 cubic centimeters of air to pass through 1 square
inch of the glass fiber mat.
In an exemplary embodiment, the dual-sided application and
penetration of the first and second binding compositions can also,
for example, render the composite board suitable for use in highly
alkaline environments by providing increased resistance to highly
basic liquids which can typically cause the decomposition of glass
fibers. For example, the composite board of the present invention
can be used in bathrooms as a tile backer.
The composite board of the present invention can also be less
irritating to the skin when handled. Since more glass fibers are
covered or encapsulated within the glass fiber mat, the composite
board can be less irritating to the hands and arms of the workers
handling and installing the building material. When the composite
board is cut, the board can release less glass fiber dust from the
at least one glass fiber mat so that less glass fiber dust contacts
exposed skin. The composite board can also be manufactured with
less chemical usage and better chemical flow. For example, when the
at least one glass fiber mat is adhered to the foam layer during
manufacture, the amount of foam material consumed by the glass
fibers is reduced or eliminated due to the dual-sided coating of
the glass fiber mat. Thus, less foam may be utilized in forming the
foam layer and less time may be required in manufacturing the
composite board.
The first and second binding compositions can include a binder and
an inorganic filler. The binder bonds the inorganic filler together
and additionally bonds the inorganic filler to the glass fiber mat.
The binder can include, for example, a latex binder, a starch or
combinations thereof. Examples of latex binders include butyl
rubber latex, styrene butadiene rubber (SBR) latex, neoprene latex,
acrylic latex and SBS latex, and can in particular include the SBR
latex. In one embodiment, each of the first and second binding
compositions can include from about 1% latex to about 15% latex,
based on the respective weight of each binding composition. In
another embodiment, each of the first and second binding
compositions can include from about 1% latex to about 5% latex,
based on the respective weight of each binding composition.
Examples of a suitable inorganic filler include calcium carbonate,
clay, talc, mica, perlite, hollow ceramic spheres or a combination
thereof. In an exemplary embodiment, the inorganic filler can
include calcium carbonate. In an exemplary embodiment, the
inorganic filler can be present in the first and second binding
compositions in an amount from about 80% to about 98%, based on the
respective weight of each composition.
Referring to FIG. 4, in an exemplary embodiment, the composite
board can include two glass fiber mats, a first glass fiber mat 20a
and a second glass fiber mat 20b. The foam layer 30 can be arranged
between and sandwiched by the first and second glass fiber mats 20a
and 20b and attached to the first and second glass fiber mats 20a
and 20b. Preferably the first and second glass fiber mats 20a and
20b are substantially fully adhered to the upper and lower surfaces
of the foam layer 30.
Any method suitable for applying a binding composition or coating
to a glass fiber mat or impregnating a glass fiber mat with a
binding composition or coating may be used to apply the first
binding composition to the upper surface of the at least one glass
fiber mat and the second binding composition to the lower surface
of the at least one glass fiber mat. The first and second binding
composition can be applied by air spraying, dip coating, knife
coating, roll coating, or film application such as lamination/heat
pressing.
For example, FIG. 2 depicts an exemplary system for roll coating
the at least one glass fiber mat with the first and second binding
compositions. Glass fiber mat 20 can be fed through a nip 50
created by a first applicator roll 60a and a second applicator roll
60b. The first applicator roll 60a can be continuously coated with
the first binding composition and the second applicator roll 60b
can be continuously coated with the second binding composition. The
first applicator roll 60a transfers a puddle of the first binding
composition to the upper surface of the glass fiber mat and the
second applicator roll 60b transfers a puddle of the second binding
composition to the lower surface of the glass fiber mat 20. Thus,
the first applicator roll 60a applies the first binding composition
to the upper surface and the second application roll 60b applies
the second binding composition to the lower surface. Metering
blades 70 can be used to remove any excess of the first and/or
second binding compositions and/or level the first and/or second
binding compositions.
FIG. 3 depicts an exemplary system for air spraying the first and
second binding compositions onto the upper and lower surfaces of
the at least one glass fiber mat 20. Glass fiber mat 20 can be fed
between a first set of spaced apart, spray nozzles 80a and a second
set of spaced apart, spray nozzles 80b. The first set of spaced
apart, spray nozzles 80a face the upper surface of the glass fiber
mat, while the second set of spaced apart, spray nozzles 80b face
the lower surface of the glass fiber mat. The first set of spray
nozzles 80a can emit the first binding composition onto the upper
surface of the glass fiber mat and the second set of spray nozzles
80b can emit the second binding composition onto the lower surface
of the glass fiber mat 20. Metering blades 70 can be used to remove
any excess of the first and/or second binding compositions and/or
level the first and/or second binding compositions.
The foam layer can be attached to the at least one glass mat by any
suitable means, for example, through use of a laminating process.
In an exemplary method of making the composite board, the at least
one glass fiber mat can be unrolled and fed along a process line.
The glass fiber mat has the first binding composition applied to
its upper surface and the second binding composition applied to its
lower surface. Thermosetting polymer foam can then be injected onto
the upper surface of the glass fiber mat. The glass fiber mat and
thermosetting polymer foam can then be sent through a laminator
wherein the thermosetting polymer foam is heated and rises, cures,
and adheres to the upper surface of the glass fiber mat. The
composite board can be further processed, for example, by being cut
into desired lengths.
In an alternative exemplary method of making the composite board, a
first glass fiber mat can be unrolled and fed along a process line.
The first glass fiber mat has the first binding composition applied
to its upper surface and the second binding composition applied to
its lower surface. Thermosetting polymer foam can then be injected
onto the upper surface of the first glass fiber mat. Subsequently,
a second glass fiber mat can be unrolled and fed along a process
line. The second glass fiber mat has the first binding composition
applied to its upper surface and the second binding composition
applied to its lower surface. The second glass fiber mat can be fed
above the thermosetting polymer foam and kept spaced apart from the
thermosetting polymer foam. The glass fiber mat and thermosetting
polymer foam can be sent through a laminator wherein the
thermosetting polymer foam is heated and rises, cures, and adheres
to the upper surface of the first glass fiber mat and the lower
surface of the second glass fiber mat. The composite board can be
further processed, for example, by being cut into desired
lengths.
The composite board may be further coated with coatings on one or
both of its sides. For example, if the composite board has a foam
layer arranged between a first glass fiber mat and a second glass
fiber mat, any existing free, uncoated surfaces of the first glass
fiber mat and/or the free surface of the second glass fiber mat may
be coated with at least one coating. In such embodiment, any
coating overlays the first or second binding composition. Coatings
include, for example, water repellent material, antifungal
material, antibacterial material, a surface friction agent, a flame
retardant material and algaecide. One type of coating may be
applied to one side or both sides of the composite board. For
example, if the composite board has a foam layer arranged between a
first glass fiber mat and a second glass fiber mat, a water
repellant material may be applied to the free surface of the first
glass fiber mat and a flame retardant material may be applied to
the free surface of the second glass fiber mat.
The composite board of the present invention can be useful in a
variety of building applications. For example, the composite board
may be used as roofing insulation, coverboard, sheathing, flooring
underlayment, and tile backer.
* * * * *